Solar roof panel system with edge and surface treatments

ABSTRACT

A roof-mounted solar power system for generating electrical power that includes a plurality of solar modules adapted for generating electrical power from sunlight, and with each of the plurality of solar modules having substantially the same size, aspect ratio and surface coloring. The plurality of solar modules are mounted on the deck of a roof to form a bank of solar modules having at least one irregular edge. The solar power system further includes one or more non-power generating edge treatments having substantially the same size, aspect ratio and surface coloring as the solar modules and that are adapted for installation along the irregular edge. Each edge treatment is adapted for a cutting away of at least one corner thereof to smooth the irregular edge of the bank of solar modules to a regular edge.

RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.17/979,082, filed Nov. 2, 2022, which claims priority to U.S. patentapplication Ser. No. 16/734,768, filed Jan. 6, 2020, which claimspriority to U.S. patent application Ser. No. 16/202,414 filed Nov. 28,2018, now abandoned, which claims priority to U.S. patent applicationSer. No. 14/042,789 filed Oct. 1, 2013, now U.S. Pat. No. 10,187,005,issue date Jan. 22, 2019, which claims benefit of U.S. provisionalpatent application no. 61/708,237, filed on Oct. 1, 2012, now expired,and entitled “Solar Roof Panel System With Edge And Surface Treatments”,which applications are each incorporated by reference as if set forth intheir entireties herein.

TECHNICAL FIELD

This application relates generally to solar power and more specificallyto electric solar collectors for placement on the shingled roof of astructure such as a residential home.

BACKGROUND

The trend toward alternate energy sources has led in recent years to ademand for wind, geothermal, solar, hydrogen, and other sources ofenergy that do not derive from fossil fuels. The capturing of solarenergy includes, without limitation, the collection and storage of heatfrom the sun and the collection and storage of electricity derived fromsunlight. In the later case, solar cells and multi-cell solar moduleshave been developed that convert sunlight directly into electricalenergy, which then may be used, stored in batteries, and/or placed backon the electrical grid. While solar modules are feasible in manyapplications, such as on industrial and commercial buildings, someconsider them unsightly for use on roofs of residential homes. Further,traditional solar modules cover the shingles of a residential home,obscuring the architectural contribution of the shingles to the home.There is a need for a system to collect solar energy from the roof of aresidential home that is not unsightly and that is integrated into andactually enhances the architectural appearance of the shingles of thehome. It is to the provision of such a system that the present inventionis primarily directed.

SUMMARY

Briefly described, one embodiment of the present disclosure comprises aroof-mounted solar power system for generating electrical power fromsunlight. The solar power system includes a plurality of solar modulesadapted for generating electrical power from sunlight, with each of theplurality of solar modules having substantially the same size, the sameaspect ratio and the same coloring of a top surface. The plurality ofsolar modules are mounted on a deck of a roof to form a bank of solarmodules having at least one irregular edge, such as an interior corneror an interior horizontal edge. The solar power system further includesone or more dummy panels which do not generate electrical power, buthave substantially the same size, aspect ratio and top surface coloringas the solar modules, and which are adapted for installation adjacentthe irregular edge. In addition, the dummy panels are also adapted forthe cutting away of at least one corner thereof to reshape the bank ofsolar and dummy panels into a solar power system having a continuousperimeter edge without interior corners and interior horizontal edges.

Another embodiment of the present disclosure comprises an edge treatmentfor a roof-mounted solar power system for generating electrical powerfrom sunlight. The edge treatment includes one or more blank panelshaving substantially the same size, the same aspect ratio and the sametop surface coloring as the size, aspect ratio and a top surfacecoloring of a plurality of solar modules mounted on a deck of a roof andthat together form a bank of solar modules having at least one irregularedge. The blank panels are adapted for a cutting away of at least onecorner thereof to smooth the irregular edge of the bank of solar modulesto a regular outside edge.

The invention will be better understood upon review of the detaileddescription set forth below taken in conjunction with the accompanyingdrawing figures, which are briefly described as follows.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a solar power system for generatingelectrical power, in accordance with a representative embodiment.

FIG. 2 is a cross-sectional view of the solar power system of FIG. 1 ,as viewed from Section Line A-A.

FIG. 3 is a cross-sectional view of the solar power system viewed fromSection Line A-A of FIG. 1 , in accordance with another representativeembodiment.

FIG. 4 is a perspective view of the solar power system of FIG. 1 , inaccordance with yet another representative embodiment.

FIG. 5 is a cross-sectional view of the solar power system of FIG. 4 ,as viewed from Section Line B-B.

FIG. 6 is a cross-sectional view of the solar power system viewed fromSection Line B-B of FIG. 4 , in accordance with yet anotherrepresentative embodiment.

FIGS. 7 and 7A are perspective and close-up views, respectively, of thesolar power system of FIG. 4 , in accordance with yet anotherrepresentative embodiment.

FIGS. 8 and 8A are perspective and close-up views, respectively, of thesolar power system of FIG. 4 , in accordance with yet anotherrepresentative embodiment.

DETAILED DESCRIPTION

Referring now in more detail to the drawing figures, wherein like partsare identified with like reference numerals throughout the severalviews, FIG. 1 illustrates a solar power system 20 for generatingelectrical power. The solar power system 20 can be mounted to the roofdeck 14 (FIG. 2 ) of a building or home 12 to form a portion of the roof10 thereof, and can include a plurality of solar modules 30 or solarshingles arranged in vertically-ascending courses 24 to form a bank ofsolar modules 26. As shown in FIG. 1 , the bank of solar modules 26 maynot cover the entire roof 10, and instead can be installed to one ofseveral roof segments or roof planes 16 that is oriented in a directionfavorable for receiving sunlight, with the remainder of the roof planesbeing covered with a more traditional roof covering system 18 such asasphalt roofing shingles, slate roof tiles, or ceramic roof tiles, andthe like.

As shown in cross-section in FIG. 2 , the solar modules 30 willgenerally be installed directly to the deck 14 of the roof 10 to formtheir own protective water-shedding and weather-resistant roof coveringsystem. In order to form a continuous water-tight barrier that preventswater from migrating downward through the vertical seams or joints 52between solar modules 30, the edges can be abutted against each otherwith an edge sealing system. In another embodiment shown in FIG. 3 , theedges of the solar modules 30′ can overlap each other to form downwardlyinclined joints 52′ that may not require additional sealing. In otheraspects, the bank 26 of solar modules 30 also may be overlaid orsupported on the existing roof covering system 18 which provides thewater-shedding and weather-resistant barrier that protects the home 12below (not shown).

In the embodiment of the solar power system 20 illustrated in FIGS. 1and 2 , each of the power-generating solar modules 30 can include aframe structure 40 having a top surface 42 upon which is supported asolar element 60, a bottom surface 44, and a thickness 43 between thetop surface 42 and the bottom surface 44 that elevates the solar element60 a predetermined distance above the roof deck 14. In addition, thesolar element 60 may comprises a substantially-transparent glass 62 orglass-like panel that covers one or more photovoltaic cells 64 locatedbelow the glass 62.

As shown in FIG. 2 , the solar element 60 may be positioned above thetop surface 42 and extend nearly from edge-to-edge over the underlyingframe 40, so that the side edges of the solar element 60 are exposed.Alternatively, as shown in FIG. 3 , the solar element 60 may bepositioned within an appropriately sized receptacle 48′ formed into thetop surface 42′ of the frame 40′, so that side edges of the solarelement 60 are protected by encircling strips of frame material 41′.Other arrangements for supporting the solar element 60 on the frame 40are also contemplated and considered to fall within the scope of thepresent disclosure. The solar element 60 generally covers as much of thetop surface 42 of the frame 40 as possible to provide the greatestamount of photo-sensitive surface area per solar module 30 that isexposed to sunlight.

The solar element 60 is typically a separately-manufactured componentthat has been provided with a predetermined size and shape which cannotbe changed or modified in the field without destroying the functionalityof the solar element 60. Thus, once the solar element 60 is manufacturedand mounted into the frame 40, the size and aspect ratio of the solarmodule 30, as well as its surface coloring which is defined by thecoloring of the glass 62 or photovoltaic cells 64, may also be fixed andcannot be altered once the unit has been manufactured or assembled.

As shown in FIG. 1 , each of the solar modules 30 in the bank of solarmodules 26 can generally have the same length 45 and width 46. In turn,these dimensions are generally defined by the size and aspect ratio ofthe solar elements 60. Each of the solar modules 30 in any particularbank of solar modules 26 are generally provided with the same length 45and width 46, both because they fit together better and because it canbe significantly more cost-effective to manufacture and supply solarroofing panels in standard sizes which have been previously engineeredto meet all the requirements of the solar module system 20. In oneexemplary embodiment of the present disclosure, for instance, the solarmodules 30 can have a length of about 65 inches and a width of about 25inches, which may be considered a balanced solution between the size ofthe solar element 60 (larger solar elements generally have a lower costper unit area than smaller solar elements) and the ease and safety for asingle individual who may be tasked with handling the panel of asteeply-sloped roof on a windy day. Of course, different banks of solarmodules 26 may have individual solar modules 30 with sizes and aspectsratios that vary considerably from those described above.

The roof plane 16 or roof segment upon which the bank of solar modules26 is to be installed is likely to have a different size and shape thanother roof planes, thus requiring some customization in the placement ofthe solar modules 30. For example, the courses of solar modules 24 canbe staggered and extended across the expanse of the roof plane 16 toprovide the greatest amount of coverage and exposure to sunlight, so asto maximum the power output from the bank of solar modules 26. Given thelarge size and aspect ratios of the individual solar modules 30,however, the outside perimeter edge 28 of the bank of solar modules 26is likely to include one or more irregular side edges. For example, theirregular side edges can include interior corners 54, interiorhorizontal edges 56, and outer edges 58 that are non-parallel with anedge of the roof plane 16. These irregular side edges can be unsightly,can reduce the ability of the bank of solar modules 26 to shed water,and can increase the likelihood that rain, snow, soot, dirt and plantmaterials such as leaves, twigs and branches may be captured and held bythe bank of solar modules 26. If not removed, the accumulated materialand moisture can result in stains and/or water damage to the roof.

To overcome these problems, in another embodiment of the solar powersystem 21 shown in FIG. 4 , the bank 27 of solar modules 30 can beprovided with edge treatments, such as one or more blank or dummy panels70 having substantially the same size, the same aspect ratio, and thesame surface coloring of a power-producing solar module 30, but withoutthe solar element 60 and associated components needed to generateelectricity from sunlight. Furthermore, each of the dummy panels 70 canbe adapted for the cutting away of at least one corner thereof, andoften an entire side edge or even a majority portion of the dummy panel,so that the remainder portions of the dummy panels 70 can fit within thebank 27 of solar modules 30 and adjacent to the irregular edges. Assuch, the frames 72 of the dummy panels 70 can align with the horizontaledges 34 and/or vertical edges 36 of the solar modules 30 to fill thespaces proximate the irregular edges, while the cut edges 77 of thedummy panels 70 re-shape the perimeter of the bank 27 of solar modules30 and dummy panels 70 to form a more-uniform and continuous outsideperimeter edge 29 without interior corners and interior horizontaledges.

As shown in FIGS. 5 and 6 , the dummy panel can include a frame that issimilar in size and shape to the frame of the solar module describedabove. In the edge-butting dummy panel 70 shown in FIG. 5 , the frame 72has top surface 74, a bottom surface 76, and an increased thickness 78that substantially matches the overall thickness of the correspondingsolar module shown above (FIG. 2 ), and with the solar element beingreplaced by the full-face top surface 74 which can be colored to matchthe appearance of the top surface 62 of the solar module 30. Similarly,the frame 72′ of the dummy panel 70′ with an overlapping-edge also has atop surface 74′, a bottom surface 76′, and an increased thickness 78′that substantially matches the thickness and profile of thecorresponding solar module shown above in FIG. 3 , and with the solarelement also being replaced by the full-face top surface 74′. Thus, itis to be appreciated that the top surfaces 74 of the dummy panels 70 canbe located at substantially the same elevations as the transparent glass62 of the solar elements 30, and can therefore provide for a bank 27 ofsolar modules 30 and dummy panels 70 having top surfaces 62, 74 that aresubstantially uniform and planar.

Alternatively, the blank or dummy panel 70 may comprise a granulatedasphaltic panel or similar product (not shown) having a thickness thatis less than the thickness of the solar modules, but still having avisible top surface that is substantially the same size (i.e. surfacearea), the same aspect ratio and the same surface coloring as thevisible top surface of the solar modules. The granulated asphaltic dummypanel is also adapted for the cutting away of a corner or side edgethereof and for installation adjacent an irregular edge of the bank ofsolar modules 27. In this embodiment, however, the top surface of thegranulated asphaltic dummy panel may be located at an elevation that isbelow the elevation of the glass 62 of the solar elements 60, but cannevertheless provide the appearance, at least from a distance or througha glancing look, of a bank 27 of solar modules 30 and dummy panels 27having a uniform and continuous outside perimeter edge 29 (FIG. 4 ).

In addition to having substantially the same surface coloring, the topsurfaces 74 of the blank or dummy panels 70 can also mimic theappearance of the top surfaces 62 of the solar modules 30 in otherrespects. For instance, the top surfaces 74 can be provided with aglossy, semi-reflective surface coating that mimics the reflectivity ofthe glass 62 of the solar elements 60 mounted into/over the top surfaces42 of the frames 40. As will be described in more detail below,moreover, the top surfaces 74 of the dummy panels 70 can also beprovided with the same surface treatments that are applied to the topsurfaces 62 of the solar modules 30, and which may operate alter thetexture or appearance of the visible portions of the bank of solarmodules 30 and dummy panels 27.

As discussed above, each of the dummy panels 70 can be adapted for thecutting away of a corner or side edge to form a cut edge surface 77 atany angle across the width or length of the dummy panel, which can thenbe aligned with the horizontal edges 34 and/or vertical edges 36 of thesolar modules 30. As such, the material 71 forming the dummy panel 70can be selected or adapted to allow for the cutting process to beperformed in the field using normal cutting tools. Furthermore, in someaspects a final cutting step can be performed after the dummy panel 70has been installed onto the roof 10 and within the bank 27 of solarmodules 30 and dummy panels 27, so as to provide an exact cut that thatprecisely matches the desired contour of the outside perimeter edge 29of the bank of panels 27.

Consequently, as can be seen in FIG. 4 , the bank 27 of solar modules 30and dummy panels 70 can have a substantially smooth and uniform topsurface which provides for the effective shedding of rain, snow and ice,as well as a uniform and continuous outside perimeter edge 29, withoutinterior corners and interior horizontal edges, that reduces thelikelihood that water, soot, dirt and plant materials may be capturedand held within an outer boundary of the bank of panels 27. In addition,the capability of cutting the blank or dummy panels 70 at any angleacross the width or length of the dummy panel allows for the outsideedges of the bank of panels to be aligned with the corners and edges ofthe roof plane, which can further help to control and guide the sheddingof water from the surfaces of the roof and to increase the overallstructural integrity of the solar power system 21.

With reference now to FIGS. 7 and 7A, and in accordance with anadditional representative embodiment, the top surfaces of the solarmodules 130 and the top surfaces 174 of the blank or dummy panels 170can include glass 162 and can be provided with one or more surfacetreatments 180 that produce the appearance of a plurality of smaller,standard-sized shingles or roofing tiles to break up or hide the truesize of the panels. In addition, the surface treatments 180 can beconfigured to substantially maintain the amount of sunlight reaching thephotovoltaic cells below the glass 162 of the solar modules 130 ascompared to solar modules without surface treatments 180. Indeed, andwithout being bound to any particular theory, it is believed that thesurface treatments 180 may be used to increase the efficiency oreffective range of power generation of the solar modules by deflecting,diffusing or otherwise redirecting the sunlight over a broader portionof the photovoltaic cells, especially when the angle of incidence of thesunlight on the solar modules is lower during the early mornings andlate afternoons.

The surface treatments 180 can take a variety of forms, including therelatively shallow surface treatments 182 shown on FIGS. 7 and 7A. Theseshallow surface treatments 182 can include etching a shape or textureinto the glass 162 of the solar modules 130 and to the top surfaces 174of the dummy panels 170 to create frosting elements 184 which canportray shadows or shading, as well as linear elements 186 which canportray the sharp edges of the non-existent shingles or tiles. As knownto one of skill in the art, the etching may be accomplished throughmechanical, chemical or optical (laser) means.

Alternatively, the frosting elements 184 and linear elements 186 canalso be provided through the application of paint or similar opaquematerial to the upper surfaces of the solar modules 130 and dummy panels170. In one aspect, the paint can be applied in the form of tiny dots,similar in method to the application of ink with an ink-jet printer. Theapplication of paint can further include variations in the density ofthe dots, such as light, medium and heavy, to provide frosting elements184 and linear elements 186 having multiple tones or shades.

As shown in FIGS. 8 and 8A, the surface treatments 280 can also includedeep surface treatments 292 such as linear channels or grooves 294formed across the expanse of the glass 262 of the solar modules 230 andthe top surfaces 274 of the dummy panels 270, and which extend deeperinto the top surfaces than the shallow surface treatments 282 describedabove. In one aspect, the linear grooves 294 can optically mimic theactual horizontal edges 234 and vertical edges 236 of the panels byrunning parallel to the edges of the panel. This can visually break upthe panels into smaller segments. In one representative embodiment thelinear grooves 294 may be formed only in the horizontal direction, whichcan provide the appearance of elongated panels or strips of tiles. Thismay be especially effective when the deep surface treatments 292 of FIG.8 are combined with the shallow surface treatments 282 of FIG. 7 toprovide a complex and nuanced optical image.

The invention has been described in terms of preferred embodiments andmethodologies considered by the inventors to represent the best mode ofcarrying out the invention. A wide variety of additions, deletions, andmodification might well be made to the illustrated embodiments byskilled artisans within the scope of the invention. For example, otherdeep surface treatments, such as sweeping curves or shapes which extendacross multiple panels, etc, as well different combinations of shallowsurface treatments 182 and deep surface treatments 292 for both artisticeffect and functional enhancement. These and other revisions might bemade by those of skill in the art without departing from the spirit andscope of the invention, with is constrained only by the followingclaims.

What is claimed is:
 1. A solar power system, comprising: a roof deck; aplurality of solar modules installed above the roof deck, wherein theplurality of solar modules comprises at least a first solar module and asecond solar module, wherein the first solar module and the second solarmodule are installed above the roof deck on a first roof plane, whereineach of the first solar module and the second solar module comprises: aplurality of side edges, and a top surface extending between the sideedges, wherein the top surface of the first solar module comprises afirst groove and a second groove, wherein the first groove extends in afirst direction, wherein the second groove extends in a seconddirection, wherein the first direction and the second direction aredifferent from one another, and a plurality of non-power generatingmodules installed above the roof deck, wherein the plurality ofnon-power generating modules comprises at least a first non-powergenerating module, wherein the first non-power generating module isinstalled above the roof deck on a second roof plane, wherein the firstroof plane is a different roof plane than the second roof plane, whereinthe first non-power generating module comprises: a plurality of sideedges, and a top surface extending between the side edges of the firstnon-power generating module, wherein the top surface of the firstnon-power generating module comprises a third groove and a fourthgroove, wherein the third groove extends in a third direction, whereinthe fourth groove extends in a fourth direction, wherein the thirddirection and the fourth direction are different from one another. 2.The solar power system of claim 1, wherein the first direction and thethird direction are the same as each other.
 3. The solar power system ofclaim 2, wherein the second direction and the fourth direction are thesame as each other.
 4. The solar power system of claim 1, wherein thesolar modules are installed in multiple rows on the roof deck.
 5. Thesolar power system of claim 1, wherein each of the top surface of thefirst solar module and the top surface of the first non-power generatingmodule has an appearance that is similar to one another.
 6. The solarpower system of claim 1, wherein the first non-power generating moduleis cuttable.
 7. The solar power system of claim 1, wherein the firstsolar module and the first non-power generating module are installed ina first row on the roof deck, wherein the first non-power generatingmodule is installed at an end of a same row.
 8. The solar power systemof claim 1, wherein the first solar module comprises at least one solarcell.
 9. The solar power system of claim 1, wherein the first solarmodule comprises a plurality of solar cells.
 10. The solar power systemof claim 1, wherein the side edges of the first solar module are exposedto an external environment.
 11. The solar power system of claim 1,wherein the first groove has a first depth, wherein the second groovehas a second depth, wherein the first depth is different than the seconddepth.
 12. A solar power system, comprising: a roof deck; a plurality ofsolar modules installed above the roof deck, wherein the plurality ofsolar modules comprises at least a first solar module and a second solarmodule, wherein the first solar module and the second solar module areinstalled above the roof deck on a first roof plane, wherein each of thefirst solar module and the second solar module comprises: a plurality ofside edges, and a top surface extending between the side edges, whereinthe top surface of the first solar module comprises a first groove and asecond groove, wherein the first groove extends in a first direction,wherein the second groove extends in a second direction, wherein thefirst direction and the second direction are different from one another,and a plurality of non-power generating modules installed above the roofdeck, wherein the plurality of non-power generating modules comprises atleast a first non-power generating module, wherein the first non-powergenerating module is installed above the roof deck on a second roofplane, wherein the first roof plane is a different roof plane than thesecond roof plane, wherein the first non-power generating modulecomprises: a plurality of side edges, and a top surface extendingbetween the side edges of the first non-power generating module, whereinthe top surface of the first non-power generating module comprises athird groove and a fourth groove, wherein the third groove extends in athird direction, wherein the fourth groove extends in a fourthdirection, wherein the third direction and the fourth direction aredifferent from one another.
 13. The solar power system of claim 12,wherein the first direction and the third direction are the same as eachother.
 14. The solar power system of claim 13, wherein the seconddirection and the fourth direction are the same as each other.
 15. Thesolar power system of claim 12, wherein the plurality of solar modulesfurther comprises a third solar module and a fourth solar module,wherein the third solar module and the fourth solar module are installedabove the roof deck in a same row.
 16. The solar power system of claim12, wherein each of the top surface of the first solar module and thetop surface of the first non-power generating module has an appearancethat is similar to one another.
 17. The solar power system of claim 12,wherein the first non-power generating module is cuttable.
 18. The solarpower system of claim 12, wherein the first non-power generating moduleis installed at an end of a same row.
 19. The solar power system ofclaim 12, wherein the first solar module comprises at least one solarcell.
 20. The solar power system of claim 12, wherein the firstnon-power generating module is adjacent to at least one of the firstsolar module or the second solar module in a same row.